A characterization of the side bonding, upset plug welding process
The goal of this investigation was to characterize the side bonding variant of the upset plug welding process. In this process an oversized plug is driven into an opening where it is welded in place with the heat of electric current. The processing parameters studied in this work were weld current, closing force, weld time, plug fit, and interfacial cleanliness. The results were measured in terms of plug displacement, metallurgical structure, and bond length. The results of the experiments indicate that force has a modest influence on cold plug displacement, but little effect on ultimate bond quality. Plug fit has a moderate influence on cold displacement. Lubricous contamination can affect a sharp increase in cold displacement. With the passage of current, the weld structure is seen to develop quickly, then reach a point of equilibrium and become independent of weld time after that. Higher levels of current bring the process to completion sooner, but given sufficient time the end results can be the same for a wide range of currents. In a quantitative way, this work presents data which facilitates optimal selection of processing parameters. Qualitatively, the information provides insight into the basic mechanisms of the process. On a conceptual level, approaches for controlling quality are presented. Most significantly, the results of the work portray side bonding, upset plug welding as a remarkably robust process, extremely tolerant of major variations in processing parameters. 1 ref., 15 figs.
- Research Organization:
- Sandia National Labs., Livermore, CA (USA)
- DOE Contract Number:
- AC04-76DR00789
- OSTI ID:
- 5892687
- Report Number(s):
- SAND-89-8242; ON: DE89015181
- Resource Relation:
- Other Information: Portions of this document are illegible in microfiche products
- Country of Publication:
- United States
- Language:
- English
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